Styrene production plant

Styrene production plant interpret mouldProject DefinitionThe aim of this paper was to design a phenylethylene plant that produces 30,000 kg/h of phenylethylene using the catalytic dehydrogenation of ethylbenzene (EB). This report determined whether the dehydrogenation of EB is an effective (both chemicly and economic entirelyy) and viable method of producing phenylethylene. The paper sought to determine this by analysing the production form, cost of the building and running a styrene plant, and the chemistry involved.Process DescriptionIncident ReviewMaterials Hazard DataRaw Materials, Intermediates, Products By-ProductsEthylbenzene is defamatory, a flammable liquid and is a severe eye irritant. It is the reactant used in the important process of the plant. It dehydrogenates to form styrene as the main reaction, but different side reactions form toluene and benzene. This chemical would stick out problems with fires on site. ethylbenzene should be kept away from the ot her flammable materials in process, to parry the risk of fire.Styrene is a flammable liquid, mildly toxic, harmful when inhaled ( for example it whitethorn cause headache, nausea, dizziness, muscle weakness produces central nervous system depression irritates nose, lungs and throat.), and it mode directs annoyance to eyes and skin. Styrene is confirmed as a carcinogen. It should be produced by the dehydrogenation of ethylbenzene. This chemical base produce major injuries if a fire starts on site. The best condition for this chemical to be stored is on site for as short a age as possible, before being transported away by the tanker. Due styrene is flammable liquid it should be stored away from both other flammable centerfields such(prenominal) as ethylbenzene, toluene and extra c atomic number 18 should be taken to inform the fire services of the danger, to ensure it is dealt with it promptly and properly. Pressure privy build in comp unmatchablent and they need to be checked for weakened points.Toluene is very(prenominal) flammable, can cause irritation to skin and is harmful if inhaled. It is formed as one of the side reactions in the reactor, when styrene reacts with the hydrogen formed. Loss of containment would cause problems, due to the additional fire risk. The chemical should be kept away from flammable chemicals. benzine can cause cancer, is toxic, very flammable, irritating to eyes and skin. It is harmful for example it can cause lung damage if swallowed. Benzene is formed in the process by the reaction of ethylbenzene and hydrogen. Benzene is the most violent chemical in this process. Loss of containment could establish very serious off-site effects. Cleaning up of any spills would be a problem, and extra care must(prenominal) be taken into account to ensure that people are trained to do so, as this chemical can destroy the environment.EffluentsSteam is used as a power in put together to keep the reaction going, and thus does not particip ate in any chemical reaction itself. It is not toxic, however large amount are required, and care must be taken that this water is taken from a able source. The water is reusable in this process. The risk of loss of containment depends greatly on the pressure of the move, excluding the temperature, it should be relatively low risk.Emissions from other facilitiesThis would need to be blameless when it is cognize what is being released by facilities near by.Support MaterialsKOH is corrosive and harmful if swallowed. It catalysts the dehydrogenation of ethylbenzene and reduces the energy required for this reaction.Fe2O3 is non toxic, has no risk to it and should not be considered as a hazardous chemical. It is used as part of the catalyst for the main reaction of dehydration of ethylbenzene. Loss of containment shouldnt cause many problems, and neither should storage or transport. at that place are no special handling problems with this chemical.Tertiary butyl catchol is toxic to aquatic organisms, can cause skin sensitisation and is an irritant. It lowers the amount of tars the styrene forms from polymerisation. Disposal of this substance would be difficult, and care must be taken to dispose of it in a way that is skilful for aquatic organisms. Relatively small amounts of it are needed, as it is just an addition to the styrene, and doesnt take part in any of the main reaction.ServicesThe services required for this chemical plant are fresh water, electrical energy and gas. around of the gas will be provided in the plant itself by the combustion of the light reaction products, but gas will still be provided.Principal Materials of ConstructionMaterials encountered during construction/demolitioni. Important physical and chemical propertiesii. Significant chemical reactionsiii. Materials toxic, reactive or severe Environmental impactiv. Estimates of registerv. Off site effects of Loss of Containmentvi. Means of handling and storagevii. Special handling proble msEnvironmental AspectsEnvironmental Impact StatementAs chemical engineers it is our duty to ensure that pollution is kept to a minimum where safety of the environment and natural habitats are key prior(prenominal)ities by safe and appropriate actor of containment and disposal of all waste and effluents involved in the formulate of styrene.Other Environmental ConsiderationsThe hobby identifies how the product (styrene) is going to be stored, controlled and monitoredProduct Styrene trouble/Harm to environment Mildly toxic, flammable, irritive to eye, inhalation may cause headache, nausea and dizziness.Means of Containment As table 1 indicates styrene would be best stored in Ny nylon, PE polyethylene, SS stainless steel or TF- Teflon containers. A thick container of this material would be most appropriate to store styrene as it offers only lissome changes in mass or dimensions of styrene. Hirst (2002, p.90).Controlling and Monitoring when exposed to styrene, resist protective clothing such as long overalls and thick appropriate gloves to avoid direct contact with the product.Additional safety precautionso both clothes which have been in contact with product should be washed and rinsed immediately.o get off ventilates in all rooms to remove any harmful vapour.This table identifies all by products and wastes produced during the manufacture of styrene and offers reasonable solutions as to how they can be disposed ofwellness ToxicologyOccupational Health StatementStatutory exposure entrapsSpecific Requirements for DesignTransport And SitingPossible Modes Of Transport For Styrene ProductionBy RoadBy RailBy FerryTransport StagesDue to the hazardous nature of the materials that we are going to be handling in order to produce styrene we have to undergo various safety precautions whilst transporting the materials.Because of the flammability hazard (in certain circumstances) and the unpleasant smell, all loading/unloading activities should preferably be carri ed out, having insure to the prevention of the ignition sources and styrene vapour emissions in the working area.An inspection of the transport equipment should be carried out by the loading terminal staff before, during and subsequently loading. The inspection list detailed inAppendix 5is recommended for use.Previous Cargoes And CleanlinessA tank that carries Styrene Monomer should not have carried the following substances as any of the last two cargoes acidulated soda Pyrolysis gasoline Fuel oils Lube oilsTanks to be loaded with Styrene Monomer should not be cleaned with materials which are reactive with Styrene Monomer or TBC, or cause increased colour, odour or a chloride problem. Salt water should never be the last wash because of possible chloride contamination.Because of the effect of the application of heat to styrene, steam cleaning of adjacent tanks to compartments which contain styrene or styrene residues is strictly not allowed.Facilities using styrene should have dev eloped and implemented a nationwide spill prevention and touch response plan.This plan should address1. Spill detection methods,2. Emergency notification procedures,3. Community contacts for notification and advice on evacuation require,4. crowd out prevention and protection,5. Provisions for spill containment/clean-up,6. Environmental protection,7. Compliance with applicable local regulations or laws.Effect of Loss of Containment on Occupied BuildingsPotential Effect From lively PlantsIit is only slightly soluble in water (approx. 300 ppm at ambient conditions) and consequently the acute hazard of spilled styrene will be very limited for most aquatic species. However styrene may cause tainting (unpleasant taste) in food from aquatic organisms exposed to low environmental concentrations. According to the measuring rod European Behaviour Classification (Bonn Agreement) styrene is classified as a floater evaporator.Styrene is a monocyclic alkenyl aromatic compound with a molecul ar exercising weight of 104. Being rather volatile and having a flash point of 32 oC, styrene is classified as a flammable substance, which in use may form flammable/explosive vapour-air mixtures. Despite its superior boiling point, styrene will eventually end up in the air.Short-term exposure to styrene in humans results in respiratory effects, such as throat irritation and lung constriction, irritation to the eyes, and neurological effects such as dizziness (see element 3 Health Aspects for to a greater extent details). To date styrene is classified in the EU as harmful by inhalation, irritating to the eyes and to the skin truly low concentrations of styrene vapour will react with bromine and with chlorine in sunlight to form an extremely potent lachrymatory agent. (causes tears to form, irritation and can even lead to blindness)Conformance With Company PoliciesCompany policies concerning Health, Safety and the Environment1. Smoking is prohibited in all areas of the premises bo th indoors and outdoors and in any other enclosed spaces. Smoking is only permitted in a specified location at a safe distance from the facility and all equipment.2. Food and drink should only be consumed in dining areas and all employees must thoroughly wash their hands prior to handling food.3. Fire extinguishers must be play in all parts of the premises. One should be in every room/corridor or other separated enclosure. It must be clearly visible and accessible. All Employees must be fully trained in their operation.4. Fire alarms must be present in all rooms/corridors and must be clearly signed and accessible at all times.5. All workers should not lift any objects which they are physically uncomfortable with lifting. They must ask for assistance during any moving process and movement of chemicals/other hazardous materials should always be supervised.6. Where necessary, workers must wear suitable physical protection. This includes hard hat, coat, gloves, goggles etc. Protection guidelines should be available in all processing areas and must be clear and visible.7. All materials presenting potential health risks must be carefully and properly contained. This should be checked prior to and after moving, and at least once periodic.8. All equipment must be maintained properly and regularly to the manufacturers guidelines. This must be carried out by someone qualified to do so and must be supervised.9. Equipment involving noble temperatures and pressures must be located at a safe distance from all areas largely populated by employees.10. Equipment conditions (temperature, pressure, flow rate etc) must be consistently monitored and alarms must be in place to detect loss of control.11. Controls must be capable of complete shutdown and isolation of any and all equipment and pipes.12. Emissions must be carefully controlled and must fall within limits set by the Environmental Health Agency.13. All the above policies must be reviewed periodical to ensure there are being upheld consistently. This must be carried out by an external professional.The styrene plant will adhere to all the policies set out above and all the policies will be considered and incorporated into the design of the plant to ensure they can be consistently and efficiently met.Consent Levels And Safety, Health And Environmental Protection CriteriaEnvironmentExact sizing of the plant is yet to be studied, but based on a plant in Somerville Rd Brooklyn in Melbourne owned by Huntsman Chemical Company of Australia Pty Ltd, it is likely to be approximately 40 hectares (400 km2). Depending on the proximity to civilisation, this area may increase to progress to a safe perimeter.Wildlife will be affected by this development and so study needs to be done into the location of the site and habitation. Some wildlife may equally be a potential hazard to the operation of the plant itself.NoiseThe exposure limit values are a daily or weekly personal noise exposure of 87 dB and a peak soun d pressure of 140 dB. Study therefore needs to be done to investigate the level of noise produced by the machines that will operate in this plant.Health EffectsAs described in instalment 2, many of the materials involved present risks to health. All outputs in the liquid phase are irritants and some are known carcinogens. Several of the gaseous outputs are asphyxiates and flammable. The following emission controls are enforced by law (time weighted average)Ethylbenzene TWA 100 STEL 125 (ppm) United Kingdom (UK)Benzene TWA 1.6 (mg/m3) United Kingdom (UK)Styrene Long-term exposure limit (8-hour TWA limit reference period) 430 mg.m-38.4 Personal Safety CriteriaNoise workers should be provided with noise protection when noise levels exceed the noise exposure limit stated above.Emissions In places of the plant where there is gaseous output, workers should be provided with dust respirators or gas masks where necessary. All workers must be given training on identifying gas leaks and eme rgency procedures.Machinery Workers should be provided with personal protection when working with machinery or handling equipment. This includes gloves, hard hat, protective boots and visibility jackets. Workers should be trained not to lift any unplumbed or dangerous material.Organisational, Human Factors Emergency RequirementsSuitability and Availability of StaffNew systems of Work and ProceduresSite Emergency Facilities and Roles/ResponsibilitiesFacilities for peak construction staffingSustainabilityEnvironmental officeThe EU authorities have concluded that styrene is not bio-accumulative and meets the ready biodegradation criteria of the 29th Adaptation to Technical Progress of the Dangerous Substances Directive. The European Environmental pretend Assessment of styrene has concluded that no classification is needed.Persistence of Styrene in the environment is very limited because of its volatility from soils and surface waters, its rapid oddment in air and its biodegradati on in soils, and surface and ground waters.Styrene is moderately toxic to aquatic organisms. Due to its high depletion rate from water the exposure rate may be very low.More details on Styrene environmental effects can be found in Section 4Environmental Aspects.What happens when styrene enters the environmentFor the most part, inert products such as plastic parts, packaging etc. introduce styrene into the environment through the manufacture and disposal processes with evidence of styrene contamination being found in air, water and ground soils. However, in unlinked liquid form it enters the environment quickly and in larger quantities through evaporation and is also further broken down by bacteria found in water and soils allowing further rapid entry. It is not expected to enter the food chain by grazing animals.How does it affect humansSurprisingly, for a fairly commonly used industrial product, little is known about the effects of styrene on us, what we do know to date is that alt hough exposure may not lead to any symptoms at all, breathing high levels of styrene for short periods can lead to possible respiratory problems and nervous system effects such as depression, tiredness, nausea, muscle weakness, ENT irritation. There is currently no test data on the effects of breathing low levels for a long time, nor is any data available on the effects of ingestion or absorption although animal studies revealed various symptoms such as damage to the brain, kidneys, liver and lung along with some reproductive effects.The International Agency for Research on pubic louse and the Environmental Protection Agency has also now determined that styrene could be a possible carcinogen to humans in airborne form and several(prenominal) studies of workers have shown that breathing styrene may cause leukemia. There is no current evidence to support any cancer or health risks for nal nished products containing styrene where skin contact or ingestion has occurred.Clearly, styrene is a toxic, dangerous product in its raw form. It nds its way into the market in either substantiality form e.g. plastic parts, packing etc. or in liquid form. It is not harmful to humans in its inert solid form although it is harmful to the environment if not disposed of correctly. It is harmful to humans in liquid form both as a nished product and during manufacture.WEALTH CREATIONThe process of producing styrene on a large scale has a major benefit particularily on the local population surrounding the styrene plant as there is a great number of jobs that are created for people. The local community can therefore take advantage of this and unemployment levels in the local area should plummet. The ordinary wealth of the community will in turn increase and so the plant is in effect responsible for the local area becoming more prosperous financially.Social DevelopmentFurther StudiesFurther Studies would have to be conducted in the following area to assure the construction of the pl ant is safe and viableWildlife in the local area Affect any emissions/noise might have.Local community whether the local community would be content with a styrene production plant in the areaNoise produced by plant equipmentEmissions of Benzene, Ethylbenzene, and Methylbenzene produced by the plants after reduction methods are complete. These gases are hazardous and have exposure limits which must be met.Emergency procedures and effects of plant layout